Plasma Treatment Casting PTC process for aluminum Gravity Die Casting GDC

1
Plasma Treatment Casting (PTC) process for
aluminum Gravity Die Casting (GDC)
Contact person Ran Rosen , Tel [phone],
Fax [phone] Email rosen-r_at_plasmatec.co.il
, website www.plasmatec.co.il
2
Plasma Treatment Casting (PTC) process for
aluminum Gravity Die Casting (GDC)

• The PTC is an add-on patented technology, and
  does not change the end product
• The PTC is commercial as of 2007
• The PTC reduces risers mass by 70-80
• The PTC increases casting productivity by 20-25
• The PTC improves the casting quality
• The PTC reduces casting process defects by 50

Contact person Ran Rosen , Tel [phone],
Fax [phone] Email rosen-r_at_plasmatec.co.il
, website www.plasmatec.co.il
3
Plasma Treatment Casting (PTC).
PTC system Electrodes
PTC advantages Saving 30 of aluminum
casting Saving 35 of sand and
binders Increasing 20 of casting productivity
Contact person Ran Rosen , Email
rosen-r_at_plasmatec.co.il , website
www.plasmatec.co.il
4
The PTC Process.
The PTC process applies plasma arc during
solidification process.The rotating plasma arc
movesalong a prescribed path, defined bya
special electrode.
Confidential
5
PTC multi plasma arcs system for complex casting
shapes.
Parallel plasma arcs on top of the risers
6
Plasma stirring effects.
Creating changing current density flow in the
molten metal.
Inducing electric and magnetic fields in the
molten metal.
Very effective stirring which creates enormous
shear forces and feeding.  
Breaking the growing dendrites, each fracture
create a new nucleation center.
Smaller and more uniform dendrite arm spacing
(DAS) and significant porosity ratio reduction.
7
Saving 10kg of the risers mass.
Reducing casting weight 31kg 21kg.
8
Saving 10kg of the risers mass.
Reducing casting weight 31kg 21kg.
9
Saving 10kg of the risers mass.
Reducing casting weight 31kg 21kg.
10
Saving 13kg of the risers mass.
Reducing casting weight 42kg 29kg.
11
Reduction of risers mass by 17kg.
Reducing casting weight 54kg
37kg.
12
PTCs Competitive Advantages for GDC cylinder
head.

• Reducing average casting weight by 10 kg
• Reducing average top sand core weight by 8 kg
• Reducing average solidification time by 60 sec
• Increasing casting line productivity by 20
• Improving casting quality
• Reducing process defect ratio
• Reducing porosity ratio by at least 50.
• Increasing elongation by at least 50

13
The PTC system includes

• An electrodes gripper which can be adopted for
  each type of casting die
• A multi DC channel power sources
• A control cabinet
• A consumable electrodes
• The PTC system is a flexible add-on device for
  existing casting cells
• The PTC applies the plasma arcs after teeming and
  during solidification

14
PTC Quality Improvement
15
Bottom of the casting
column
16
Bottom of the casting
column
17
Mechanical properties in the bottom of the casting
1 2 3 4
18
Mechanical properties in the column area
column
19
Quality Conclusion

• Casting better quality in addition to reducing
  casting weight by 30-40.
• Reducing solidification cycle time by 30-35.
• Improving mechanical properties by the PTC.
• Significant improvement in the elongation
  percentage (A )
• Form 3.48 to 5.70, increase of 146 in the
  bottom
• From 2.62 to 5.95, increase of 224 in the
  column (top)
• Significant improvement in the porosity
  percentage
• From 0.012 to 0.0095, reduction of 20 in the
  bottom
• From 0.08 to 0.027, reduction of 66 in the
  column (top).